ES2855111T3 - Procedure for manufacturing a decorated wall or floor panel - Google Patents

Abstract

Procedure for the manufacture of a decorated wall or floor panel (10), which presents the procedural steps: a) the provision of a plate-shaped support (12), b) the application of a decorative design ( 32) that reproduces a model of decorative design, on at least a partial area of the plate-shaped support (12), c) the application of a covering layer (40) on the decorative design (32), presenting the layer of coating (40) a radiation curable bond, and d) curing the coating layer (40), characterized in that the coating layer (40) is cured using two radiators directly in succession, the first radiator (58) emitting radiation with a different wavelength compared to the radiation from the second radiator (60), and the first radiator (58) emitting radiation with a maximum radiation in a wavelength range between greater than or equal to 395 nm and less than or equal to 445 nm, and the intensity being d and radiation of the first radiator with respect to the intensity of radiation of the second radiator in a ratio between greater than or equal to 0.75 / 1 and less than or equal to 1 / 0.75.

Description

DESCRIPTION

Procedure for manufacturing a decorated wall or floor panel

The present invention relates to a process for the manufacture of a decorated wall or floor panel. This type of decorated plates are known per se, the term wall panel also being understood as panels suitable for covering ceilings. They usually consist of a support or core made of a solid material, for example a wood material, which is provided on at least one side with a decorative layer and a cover layer as well as, if necessary, additional layers, for example, a wear layer arranged between the decorative layer and the cover layer. Usually, the decorative layer is a printed paper that is impregnated with an aminoplast resin. Also the cover layer and the other layers are generally made from aminoplast resin.

From US6,888,147B1 a process for the manufacture of a panel is known. In this procedure disclosed by this document, a decorative design is applied on a core, after which the decorative design is provided with a layer of varnish.

Document WO2015 / 128255 describes a process for the manufacture of a decorative panel. In order to be able to generate a particularly realistic perception of a structuring also in a coating layer containing varnish, the procedure comprises the procedural steps: a) making a support available, b) applying a decorative design on at least one partial area of the support, c) the application of a coating layer containing varnish on the decorative design, the procedure being characterized in that d) the coating layer containing varnish is partially cured, d1) performing a partial curing of the coating layer coating under the formation of a curing gradient, and the curing gradient being formed in the direction of the thickness of the coating layer, such that a surface area of the coating layer is cured stronger compared to one area, located downstream of the coating layer, and e) following only partial curing of the coating layer, it is provided with a structurec ion, and f) process step e) is carried out at least partially by negative structuring; and g) the coating layer containing varnish is subjected to a final cure after process step e).

Document DE202016101306U1 discloses a support material for the manufacture of a decorated wall or floor panel as well as a floor panel having such a support material, as well as a method for the manufacture of a wall panel or decorated floor.

Document US6888147B1 discloses a process for the manufacture of a decorative surface element, the element comprising a base layer and a decorative top surface. A radiation curable varnish is printed, in a predetermined pattern, as a top coat on the decorative top surface. Radiation curable varnish covers only parts of the top decorative surface, so the varnish is subjected to radiation, thereby curing. In this way, a surface structure is achieved.

However, in certain fields of application, and especially in the case of the need for stable and easy-to-manufacture panels, the processes known from the state of the art still offer potential for improvement.

Therefore, the present invention aims to provide an improved method for manufacturing decorated wall or floor panels.

This objective is achieved by a method according to claim 1. Preferable embodiments of the invention are described in the dependent claims, in the description or in the figures, being able to represent features described or indicated in the dependent claims or in the description or in the figures, individually or in any combination, an object of the invention, if the context does not unequivocally result otherwise.

The invention therefore proposes a process for the manufacture of a decorated wall or floor panel, which has the following process steps:

a) the provision of a plate-shaped support,

b) the application of a decorative design that reproduces a decorative design model, on at least a partial area of the plate-shaped support,

c) applying a cover layer over the decorative design, the cover layer presenting a radiation curable bond, and

d) curing of the coating layer,

characterized in that the coating layer is cured using two radiators immediately in succession, the first radiator emitting radiation with a different wavelength compared to the second radiator, and emitting the first radiator (58) a radiation with a maximum of radiation in a wavelength range between greater than or equal to 395 nm and less than or equal to 445 nm, and the radiation intensity of the first radiator being with respect to the intensity of radiation from the second radiator in a ratio between greater than or equal to 0.75 / 1 and less than or equal to 1 / 0.75.

The procedure described above offers significant advantages over state-of-the-art solutions. The process described above therefore serves for the formation of a decorated wall or floor panel. By the term "decorated wall or floor panel" or "decorative panel" is understood in the sense of the invention especially wall, ceiling, door or floor panels, which have a decorative design applied on a support plate . Decorative panels are used in a multifaceted way, both in the field of interior finishing of venues, as well as for the decorative cladding of buildings, for example, in trade fair construction. One of the most frequent fields of use for decorative panels is their use as floor covering. Decorative panels often feature a decorative design intended to imitate a natural material.

Examples of this type of imitated natural materials are types of wood such as maple, holm oak, birch, cherry, ash, walnut, chestnut, wengú, or exotic woods such as panga-panga, mahogany, bamboo and bubinga. Furthermore, natural materials such as stone surfaces or ceramic surfaces are frequently imitated.

The procedure described above presents, according to procedure step a), the provision of a support in the form of a plate. By a "plate-shaped support" is understood in the sense of the present invention a natural material such as a wood material, a fiber material or a material that comprises a synthetic material and is made in the form of a plate. , being able to serve especially as a core or as a base layer of the panel to be manufactured. For example, the plate-shaped support can confer or contribute to the panel already adequate stability. Furthermore, the plate-shaped support can already predefine the shape and / or size of the panel to be manufactured. However, the plate-shaped holder can also be provided as a large plate. A large panel in the sense of the invention is in particular a support, the dimensions of which exceed by a multiple the dimensions of the final decorative panels and which is divided into a corresponding plurality of decorative panels in the course of the manufacturing process, for example by means of Sawing or cutting by laser or water jet.

For example, a support can be made of a natural material, a synthetic material, or a composite material of wood and synthetic material (WPC). Layer structures of various of the mentioned materials can also be used, for example plasterboard or wood and synthetic layer boards. For example, the support plate can be made from a thermoplastic, elastomeric, or duroplastic synthetic material. According to the invention, mineral plates such as natural and artificial stone plates, concrete plates, gypsum fiber plates, so-called WPC plates (made of a mixture of synthetic material and wood), as well as plates of natural raw materials such as cork and wood. According to the invention, biomass plates such as straw, corn straw, bamboo, leaves, algae extracts, hemp, oil palm fibers can also be used as natural material. Likewise, within the framework of the process according to the invention, recycled materials can be used from the aforementioned materials. In addition, the plates can be made of a natural cellulose material, for example paper or cardboard.

Wood materials in the sense of the invention are in addition to solid wood materials, also materials such as cross-laminated wood, glued laminated wood, ribbed plywood, veneer wood, multi-laminated wood, veneer strips and plywood flexible. Furthermore, wood materials within the meaning of the invention are also understood to mean wood chip materials such as chip press boards, extruded boards, oriented strand boards (Oriented Structural Board, OSB) and wood chip strips as well as wood fiber materials such as wood fiber insulation boards (HFD), medium and hard fiber boards (MB, HFH), as well as in particular medium density fibreboards (MDF) and high density fibreboards density (HDF). Also modern wood materials such as wood and polymer materials (Wood Plastic Composite, WPC), sandwich boards of a lightweight core material such as foam, hard foam or cellular paper, and a layer of wood applied over these, as well as wood chip boards bonded with minerals, for example with cement, constitute wood materials in the sense of the invention. Cork also constitutes a wood material in the sense of the invention.

In the sense of the invention, the term fiber materials means materials such as paper and non-woven fabrics based on vegetable, animal, mineral or synthetic fibers, as well as cardboard. Examples of vegetable fiber materials are, in addition to papers and non-woven fabrics made of cellulose fibers, biomass plates such as straw, corn straw, bamboo, leaves, extracts of algae, hemp, cotton or fibers of oil palm tree. Examples of animal fiber materials are, for example, keratin-based materials such as wool or horsehair. Examples of mineral fiber materials are mineral wool or glass wool.

Furthermore, the support can be a support based on synthetic material, that is to say, for example, it can have a synthetic material or consist of this. Examples of thermoplastic synthetics are polyvinylchloride, polyolefins (for example polyethylene (PE), polypropylene (PP), polyamides (PA), polyurethanes (PU), polystyrene (PS), acrylonitrile-butadiene styrene (ABS), polymethylmethacrylate (PMMA) , polycarbonate (PC), polyethylene terephthalate (PET), polyetheretherketone (PEEK) or mixtures or copolymers of these. Synthetics can contain the usual fillers, for example calcium carbonate (clay), aluminum oxide, silica gel, flour quartz, wood flour, gypsum, they can also be dyed in a known manner, in particular it can be provided that the support material has a flame retardant.

Especially thermoplastic plastics also offer the advantage that the products made from them can be recycled very easily. Recycled materials from other sources can also be used. In this way, another possibility of reducing manufacturing costs results.

It may be preferable if the support is a support containing synthetic material presenting a support material with a matrix material containing synthetic material, in which a material of solid substance is embedded especially with a particle size less than or equal to 600 pm . Furthermore, it may be preferable that the matrix material comprises polypropylene, for example in the form of LDPE, the polypropylene being able to have a mixture of a homopolymer and a copolymer. With regard to the homopolymer and copolymer distribution it may be preferable that the homopolymer is present relative to the polypropylene in a part of> 10% by weight to <40% by weight, for example in a part of> 20% by weight at <30% by weight, for example in a part of> 23% by weight to <28% by weight, and / or that the copolymer is present with respect to polypropylene in a part of> 60% by weight at <90 % by weight, for example, in a part of> 70% by weight to <80% by weight, for example, in a part of> 72% by weight to <76% by weight, the polypropylene being composed of the homopolymer and the copolymer.

The solid substance can be for example a wood material such as wood flour, or another material such as a component of the rice plant, for example rice bran, rice carving and rice husk, cellulose or a mineral material such as rock flour, clay or other inorganic mineral materials. It may be particularly preferable for the solid substance to consist of talc or, for example, to consist of talc. Solid substances can basically be present in the form of chips, shavings, flour or fibers. As regards the use of talc as a solid, it may be advantageous that, especially in this embodiment, a high stability can be made possible. Furthermore, such a backing material can enable improved moisture resistance, especially with reduced swelling due to moisture or heat. Talc is understood in a known manner a magnesium silicate hydrate which can have, for example, the molecular formula Mg ³ [Si ⁴ Oiü (OH) ² ].

In a particularly preferred embodiment, it may be advantageous if the solid substance material is formed at least 50% by weight, relative to the solid substance material, of talc, the matrix material being present, relative to the support material, in an amount of> 30% by weight to <70% by weight, for example, from> 35% by weight to <42% by weight, and the solid substance material being present, relative to the support material, in a amount from> 30% by weight to <80% by weight, for example, from> 65% by weight to <73% by weight, and the support material and the solid substance material being present together, with respect to the material of support, in an amount> 95%.

Basically, such a support can be made available or realized, as is known for decorative panels. For example, a support of a granular starting material can be made available which is pressed under pressure and temperature to form a corresponding plate-shaped support, this example being by no means exhaustive.

Likewise, the method comprises, according to process step b), the application of a decorative design that imitates a decorative design model, on at least a partial area of the plate-shaped support.

By a "decorative pattern model" in the sense of the present invention is meant in particular an original natural material of this type or at least one surface thereof, which must be imitated or copied by the decorative pattern. The application of the decorative design can be carried out for example by applying a printed paper or an unprinted or partially printed paper, which is then printed. Alternatively, the decorative design can be printed directly on the support or on a suitable printing background, as described below.

In order to apply a decorative pattern, first of all, a decorative pattern background can be applied on at least a partial area of the support. For example, a primer can be applied first as a decorative design background especially for printing processes eg with a thickness of> 10 | jm to <60 | jm. As a primer, it is possible to use a radiation-curable liquid mixture based on a urethane or a urethane acrylate, optionally with one or more of a photoinitiator, a reactive diluent, a UV stabilizer, a rheological agent such as a thickener, an antiradical agent, a leveling agent, an antifoam or a preservative, a pigment and / or a colorant.

In addition to the use of a primer, it is possible to apply the decorative design on a decorative paper on which a corresponding decorative design can be printed and which can be provided for example by means of a layer of resin as a bonding agent, previously applied on the medium. In addition, a resin can be applied to the paper as a printing background, which as a resin component can have at least one compound selected from the group consisting of melamine resin, formaldehyde resin, urea resin, phenolic resin, epoxy resin, unsaturated polyester resin, diallyl phthalate, or mixtures of these. In the process according to the invention, the primer can be applied to the support plate preferably by means of rubber cylinders, a casting machine or by spraying. Preferably, the primer is applied in an amount between> 1 gm2 and <100 gm2, preferably between> 10 gm2 and <50 gm2, especially between> 20 gm2 and <40 gm2 Following the application of the primer on the support surface irradiation occurs with a radiation source with a suitable wavelength.

As an alternative or in addition to the primer, for example on the primer, an adherent primer can also be applied directly on the support or on the primer. For a decorative design of particularly high optical quality, it is possible, for example, to apply a white-tinted adherent background which can, for example, have white pigments. For example, the adhesive primer can be applied in two layers. It may be especially preferable for the adherent background to be radiation curable, eg UV curable. Then, a first adherent undercoat layer may preferably be cured prior to the application of another adherent undercoat layer and / or prior to printing of the decorative design. For example, the adhesive primer can have polyurethane, for example be made as a polyurethane varnish, and be provided, for example, with white pigments.

According to another embodiment of the method, the decorative pattern or the decorative layer can be applied by direct printing. By the term "direct printing" is understood in the sense of the invention the application of a decorative design directly on the support of a panel or on a layer of non-printed fiber material, applied on the support. Contrary to conventional methods in which a previously printed decorative layer is applied to a support, in direct printing, the printing of the decorative design is carried out directly within the framework of panel manufacturing. Different printing techniques can be used, such as flexography, offset printing or screen printing. In particular, digital printing techniques such as ink jet processes or laser printing processes can be used. The printing processes mentioned above are particularly sophisticated and advantageously suitable especially for the manufacture of panels, in order to be able to apply a decorative design that is faithful to detail and identical to the pattern. In the sense of the invention, by direct printing is also understood the application of the decorative design by means of printing techniques on a printable layer, previously applied on the support. Such a printable layer can be formed, for example, of a primer layer applied in the liquid state and subsequently cured, or of a pre-applied printable layer of foil, paper or non-woven fabric.

In particular, a digital printing method may be suitable for the method described above, since the three-dimensional decorative design data is preferably made available electronically or digitally. This can be valid for example both for data stored in a database, and for data determined in situ by a three-dimensional scanner. Therefore, especially by means of digital printing methods, the decorative design data made available can be used directly without intermediate steps, which means that, especially in this embodiment, the method can be applied with a particularly low effort and in an efficient manner. especially economical. Furthermore, using digital printing methods, it is possible to carry out each printing process individually, so that a particularly large application range as well as dynamic adaptation to the desired product are possible.

The decorative layer or the decorative pattern can be formed from a specially radiation curable paint and / or ink. For example, a UV-curable paint or ink can be used.

Furthermore, if necessary, initially, for example before printing, a pre-treatment of the substrate for electrostatic discharge and, optionally, subsequent electrostatic charging can be carried out. This can be used in particular to avoid the appearance of blurring during the application of the decorative design.

According to another embodiment of the method, the decorative layers or the decorative pattern can respectively be applied with a thickness in a range of> 5 | jm to <10 | jm. For example, the decorative layers can be applied respectively with a thickness of the order of 8 µm. Especially in this embodiment or with this type of thickness of the individual decorative layers, by means of a particularly thin construction of the decorative layers and thus a high-precision variability of the surface application or the coating of a layer by the applied decorative layer respectively, an impression that is particularly identical to the pattern of the decorative design or of the panel can be achieved. The decorative design model can be adapted to the desired product.

Subsequently, according to process step c), a coating layer is applied to the decorative pattern, the coating layer having a radiation-curable bond. By a protective or covering layer is meant in particular a layer of the type which protects underlying layers against wear and which can furthermore serve to receive a structure. Especially, a plurality of coating layers are provided on the decorative design to protect it. The realization of the cover layer (s) is described in detail below.

The top coat can have an acrylate-based varnish. In particular, the cover layer can have one or more acrylates, which in particular can be modified by polyurethane (PU) or acrylate / polyurethane systems can be used. Furthermore, it can be provided that the coating layer is used as a varnish, for example as a radiation-curable or at least partially radiation-curable composition, for example based on an epoxy varnish or a urethane acrylate. In particular, varnish systems of this type can form a particularly scratch- and impact-resistant coating layer, which can confer special strength on the decorative panel to be manufactured. The present invention makes it possible in particular to provide such varnish systems with negative structuring in order to enable particularly high-quality printing of the framework, with the advantages of the varnish layer.

The cover layer can, for example, have a layer thickness between> 100 µm and <5 mm, preferably between> 0.5 mm and <2.5 µm.

For example, it can be provided that two cover layers are provided, or that the cover layer is made of two layers. In this case, the layers can be made of the same material, especially varnish, or of different materials, especially different varnishes. A lower protection layer can have a structure and the upper protection layer can cover the lower protection layer. In this embodiment, provision can be made for the lower layer to have a comparatively higher viscosity during application, in order to be able to maintain stable structures even before curing, and / or for the upper layer to have a comparatively low viscosity to be able to form a homogeneous finish. Furthermore, provision can be made for the lower layer to have a greater thickness than the upper layer. In this way, the lower layer that can serve as a structural varnish can be applied for example in an application amount of> 30 g / m2 to <40 g / m2, while the upper layer that can serve as a topcoat varnish can be applied approximately at an application rate of> 10 g / m2 to <15 g / m2.

It can be provided that the coating layer contains hard substances such as titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, aluminum oxide (corundum), oxide zirconium or mixtures of these, to increase the wear resistance of the layer. It can be envisaged that the hard substance is contained in an amount between 5% by weight and 40% by weight, preferably between 15% by weight and 25% by weight in the wear layer composition. Preferably, the hard substance has an average grain diameter between 10 pm and 250 pm, more preferably between 10 pm and 100 pm. In this way, it is advantageously achieved that the coating layer composition forms a stable dispersion and that a demixing or deposition of the hard substance in the coating layer composition can be avoided.

To form a corresponding coating layer, in one embodiment it may be provided that the radiation-curable composition containing hard substance is applied in a concentration between 10 g / m2 and 250 g / m2, preferably between 25 g / m2 and 100 g / m2. The application can be carried out for example by means of cylinders, such as rubber cylinders or by means of a casting device.

It may be envisaged that at the time of application of the coating layer composition, the hard substance is not contained in the composition, but spreads as particles on the applied coating layer composition and the latter is subsequently cured in a manner. radiation induced.

Especially, a structuring, especially a surface structuring that matches the decorative pattern, can be incorporated into the cover layer by incorporating pores, which is also called a synchronous pore. This can be done in particular by a so-called negative structuring, in such a way that, by means of a punching means such as a punching core or a punching cylinder, the cover layer is provided with a structure, such that it is formed by pressure. in the coating layer. To do this, the cover layer can be initially partially cured, then provided with a structure, and then finished by curing.

In the case of the formation of the coating layer with varnishes, the structure can also be incorporated by means of a so-called positive structuring in which the structures are built by applying a layer of varnish and especially by the selective application of the raised areas of the structure. This is often done by negatively structured punching means capable of applying the varnish layer accordingly.

In addition, positive structuring can be realized by printing a structure, for example, by printing a varnish, if necessary, in several layers. It can therefore advantageously be provided that process step c) is carried out at least in part by means of a digital printing process. In this embodiment, therefore, a structure can be applied in a particularly advantageous way. The fact is that by printing a structure, it can be matched to the decorative design with maximum pressure and particularly advantageously as a synchronous pore. For this, for example, for the printing of the decorative pattern, corresponding three-dimensional decorative pattern data can be used to enable an optical appearance, if possible identical or almost identical to the pattern pattern, with a corresponding haptic structure. Printing can be carried out for example by means of an ink jet printer or a laser printer.

It can be advantageous if the structure is not printed directly on the decorative design, but if at least one, for example two additional layers of the cover layer or protective layer are arranged approximately below the structural layer. This layer or these layers can be applied in a known manner, for example by means of a roll application or the like. It may be possible to cure the individual layers underneath the framework, for example, using second radiators, the embodiments of which are described in detail, prior to printing the framework. For example, a first layer of an abrasion resistant layer can be applied, this can be cured, and an additional abrasion resistant layer can be applied and cured before printing the framework. The abrasion resistant coating layers or layers may be provided with abrasion resistant particles, as explained above.

In principle, it can be provided that the cover layer and thus some, several or all of the layers of the cover layer are provided with abrasion resistant particles.

Before applying the abrasion resistant layers, an adherent primer can be applied over the decorative design. For example, a UV curable adherent primer can be applied. As an adhesive primer, it is possible, for example, to use a varnish system that is particularly UV-curable, such as an acrylate-based varnish system.

Also the printed structure of the cover layer can be cured by a plurality of radiation units. Curing with different wavelengths can be particularly advantageous, since in this way a particularly fast and effective curing can be carried out, which can lead to an advantage in terms of the stability of the printed structure and therefore the stability long-term or abrasion resistance of the panel produced. For example, the framework can be printed by multiple application, with each layer being able to cure before the application of another layer.

Especially if a structure is printed using a varnish, where one or more abrasion resistant cover layers or layers are arranged below the printed structure, it may be advantageous to apply a top layer on the printed structure on the printed structure. This layer in turn can be formed by a varnish, such as an acrylic varnish, which can be applied by conventional procedures. This end layer can further improve the stability of the layer construction and further improve the appearance of the structure.

Basically, it can be envisaged that all the layers above the decorative design are UV radiation curable and cure before the application of another layer, especially using a plurality of radiators or a plurality of wavelengths, as described in detail. In another point. In addition, some or all of the layers may have abrasion resistant particles.

Furthermore, without additional steps, it is possible without problems and with high precision to generate a surface structuring that matches the image of the decorative design. By a surface structuring that coincides with the image of the decorative design, it is understood that the surface of the decorative panel has a perceptible structure in a haptic shape, the shape and pattern of which correspond to the optics of the applied decorative design to obtain a reproduction that is as faithful as possible to the original. made of a natural material, also in terms of haptics.

In the method described above, it is further provided that the coating layer is cured using a first radiator and a second radiator, the first radiator emitting radiation with a different wavelength compared to the second radiator. This process step in particular can offer advantages over state-of-the-art solutions.

By the fact that the coating layer is cured using a first radiator and a second radiator, with the first radiator emitting radiation with a different wavelength compared to the second radiator, the curing performance of the coating layer can be remarkably improved. covering. In detail, by such a curing process with at least two different wavelengths an improved degree of curing can be made possible. In this way, if necessary, the duration of action of the radiation can be reduced, which can optimize process times.

In addition, an improved degree of curing can enable the coating layer to exhibit stability. increased, so that damage during transport or use can be minimized. In this way, it can further be made possible that the structures incorporated in the covering layer are maintained even under high stress, which can improve the optical impression even after heavy use.

Furthermore, it was surprisingly found that an improved adhesion of the covering layer to the underlying decorative pattern can be made possible by the process described above. Also in this way, the stability of the panel can be further improved, which can lead to the advantages mentioned above.

By respectively radiation with different wavelengths is meant in particular a first radiation and a second radiation which have radiation maxima in at least one different position. For example, patterns of radiation maxima may be present which differ entirely or at least in part by position or wavelength and / or, optionally, intensity.

According to the invention, the first radiator emits radiation with radiation maxima in a wavelength range between greater than or equal to 395 nm and less than or equal to 445 nm. Additionally, it may be provided that the second radiator emits radiation with radiation maxima in a wavelength range between greater than or equal to 200 nm and less than or equal to 440 nm. Surprisingly, it has been shown that a combination of the aforementioned radiators can improve the advantages in terms of process control and the stability of the obtained product.

As a non-exhaustive example, it may be provided that the first radiator is a gallium radiator and that the second radiator is a mercury radiator. Especially a combination of a gallium radiator and a mercury radiator can make it possible to fulfill the above-mentioned wavelength ranges and thereby realize the advantages in terms of process control and the stability of the obtained product.

According to the invention, it is provided that the radiation intensity of the first radiator with respect to the radiation intensity of the second radiator is in a ratio between greater than or equal to 0.75 / 1 and less than or equal to 1 / 0.75. In this way, a substantially homogeneous intensity of the two radiators can be made possible, which can further improve the curing result. Preferably, it may be provided that the radiation intensity of the first radiator relative to the radiation intensity of the second radiator is in a ratio between greater than or equal to 0.9 / 1 and less than or equal to 1 / 0.9. Furthermore, it may be preferable that the duration of action, for example, with a displacement speed of the support of 25 to 35 m / s during curing, is in a period of time of approximately one second, so that depending on A basically variable source of radiation may suffice with a duration of action of the total radiation of less than 1 second at one position.

It may also be preferable that the first radiator and the second radiator are oriented in such a way that the radiation from the first radiator and the radiation from the second radiator strike at least in part at different positions of the covering layer and that therefore the layer coating is treated first by the first radiator and then by the second radiator. It can be provided that the first radiator and the second radiator are oriented in such a way that the radiation from the first radiator and the radiation from the second radiator all strike at different positions on the covering layer or that the first radiator and the second radiator are oriented in such a way that the radiation from the first radiator and the radiation from the second radiator strike partly at different positions of the covering layer and partly at an identical position of the covering layer, for example, by scattering the radiation. In this embodiment, therefore, the cover layer can be cured first by radiation of one wavelength and then by radiation of another wavelength. Surprisingly, it has been shown that this embodiment can also provide advantages in terms of curing. In particular, the treatment with different wavelengths can be more specific with respect to the respective wavelength, which makes it possible to adapt the curing with respect to the respective field of application, that is, for example, with respect to the specific composition of the coating layer. In particular in this embodiment, provision can be made for the coating layer to be first treated with radiation with radiation maxima in a wavelength range between greater than or equal to 395 nm and less than or equal to 445 nm, and then with radiation with radiation maxima in a wavelength range between greater than or equal to 200 nm and less than or equal to 440 nm. For example, the coating layer can be treated first by a gallium radiator and then by a mercury radiator. Surprisingly, it has turned out that especially in this embodiment a particularly preferable curing can be carried out.

Furthermore, it may be advantageous if the first radiator and the second radiator are oriented in such a way that the radiation from the first radiator and the radiation from the second radiator strike at least in part at an identical position of the covering layer. In this embodiment, therefore, it can be provided that the coating layer is treated at least in part simultaneously by the first radiator and the second radiator or by the corresponding radiation from the first radiator and the second radiator. For example, the radiation from the first radiator and that of the second radiator can totally hit the same area of the covering layer. In this embodiment, curing can be possible particularly quickly, which can make possible short process and therefore an economical manufacture.

In the following, the invention is explained further with the aid of the figures as well as an embodiment example.

Figure 1 schematically shows an embodiment of a method for manufacturing a decorated panel;

Figure 2 shows a detailed view of a radiation unit in a first embodiment; and Figure 3 shows a detailed view of a radiation unit in another embodiment.

In FIG. 1 a process for the manufacture of a decorated wall or floor panel 10 is schematically represented.

A conveyor device 100 is shown, on which an intermediate product having a support 12 is conveyed in the direction of arrow 110. The support 12 can be made available in a known manner and can basically be formed of a suitable material.

First of all, it is envisaged that by the application device 14 a primer 16 is applied to the support 12. The primer 16 can be curable by UV radiation and be cured by the radiation unit 18. Following the application of the primer 16, a two-layer adherent white background 24 can be applied by the application devices 20, 22. The adherent white background 24 in turn can be UV radiation curable and be cured by the radiation unit 26, 28, especially after the application of each layer.

Primer 16 or adherent white background 24 serve as the printing background. Therefore, using a digital printing unit 30 an impression of the support 12 is made forming a decorative pattern 32.

Subsequently, by means of an additional application unit 34, an adhesive primer 36 which is particularly UV-curable can be applied and can be cured by the radiation unit 38. The adhesive primer 36 serves as the basis for a cover layer 40. The coating layer Coating 40 may have a plurality of layers 40 ', 40 ", especially featuring a radiation-curable varnish, which can be applied by application devices 42, 44 and which after application by radiation units 46, 48 can be cured by radiation units 46, 48.

Furthermore, the cover layer 40 comprises a further layer 40 '”which has a structure especially in the sense of a synchronous pore. For this, an additional digital printing unit 50 is provided which prints the layer 40 '"in the sense of a positive structuring to thereby generate a defined structure. Subsequently, the layer 40 '"can be immediately cured by the radiation unit 52, or, by the application unit 54, a top layer 56 can be applied and then a curing can be carried out.

Figures 2 and 3 respectively show an embodiment of the radiation unit 52, the indications made here basically being valid for any of the radiation units 16, 26, 28, 38, 46, 48 described. In a particularly preferable way, the indications made can serve, in addition to the radiation unit 52, for the radiation units 18, 26 and 28.

It can be seen that for curing the coating layer 40, such as the layer 40 '”designated as the structural layer, the radiation unit 52 can have a first radiator 58 and a second radiator 60, the first radiator being provided 58 emits radiation with a different wavelength compared to the radiation from the second radiator 60. Especially, the first radiator 58 is a gallium radiator and the second radiator 60 is a mercury radiator. By providing the first radiator 58 and the second radiator 60, a particularly advantageous curing can be carried out.

According to FIG. 2, it is provided that the first radiator 58 and the second radiator 60 are oriented in such a way that the radiation from the first radiator 58 and the radiation from the second radiator 60 strike at least in part in an identical position of the covering layer. 40.

A preferable embodiment is represented in FIG. 3, according to which the first radiator 58 and the second radiator 60 are oriented in such a way that the radiation from the first radiator 58 and the radiator from the second radiator 60 impinge at least in part at positions different from the cover layer 40.

Reference signs

10 Wall or floor panel

12 Support

14 Application device

16 Primer

18 Radiation unit

20 Application device

Application device Sticky white background Radiation unit

Radiation unit

Digital printing unit Decorative design

Application device Adherent bottom

Radiation unit

Coating layer

'Cover layer layer' Cover layer layer '”Cover layer layer Application device Application device Radiation unit

Radiation unit

Digital printing unit Radiation unit Application device End layer

Radiator

Radiator

0 Conveyor device

0 Arrow

Claims (11)

1. Procedure for the manufacture of a decorated wall or floor panel (10), which presents the procedural steps: a) the provision of a plate-shaped support (12), b) the application of a decorative design (32) that reproduces a decorative design model, on at least a partial area of the plate-shaped support (12), c) applying a cover layer (40) over the decorative pattern (32), the cover layer (40) presenting a radiation-curable bond, and d) curing the cover layer (40), characterized in that the coating layer (40) is cured using two radiators directly in succession, the first radiator (58) emitting radiation with a different wavelength compared to the radiation from the second radiator (60), and emitting the first radiator ( 58) radiation with a radiation maximum in a wavelength range between greater than or equal to 395 nm and less than or equal to 445 nm, and the radiation intensity of the first radiator being relative to the radiation intensity of the second radiator in a ratio between greater than or equal to 0.75 / 1 and less than or equal to 1 / 0.75. Method according to claim 1, characterized in that the second radiator (60) emits radiation with radiation maxima in a wavelength range between greater than or equal to 200 nm and less than or equal to 440 nm. Method according to one of the preceding claims, characterized in that the first radiator (58) and the second radiator (60) are oriented in such a way that the radiation from the first radiator (58) and the radiation from the second radiator (60) impinge , at least in part, at different positions of the cover layer (40). Method according to one of Claims 1 or 2, characterized in that the first radiator (58) and the second radiator (60) are oriented in such a way that the radiation from the first radiator (58) and the radiation from the second radiator (60 ) impinge, at least in part, in an identical position of the covering layer (40). Method according to one of the preceding claims, characterized in that a radiation-curable varnish is applied as the cover layer (40). 6. Process according to claim 5, characterized in that the radiation curable varnish is an acrylic varnish. Method according to one of the preceding claims, characterized in that the coating layer (40) is provided with abrasion resistant particles. Method according to one of the preceding claims, characterized in that method step c) is carried out, at least in part, by means of a digital printing method. Method according to one of the preceding claims, characterized in that method step b) is carried out by means of a digital printing method. Method according to one of the preceding claims, characterized in that the support (12) has a matrix material and a solid material distributed in the matrix material, the material being formed from solid substance at least 50% by weight , with respect to the solid substance material, by talc, the matrix material being present, with respect to the support material, in an amount of> 30% by weight to <70% by weight, and the solid substance material being present, with respect to the support material, in an amount of> 30% by weight to <70% by weight, and the support material and the solid substance material being present together, with respect to the support material, in an amount> 95 %. Method according to claim 10, characterized in that the matrix material comprises polypropylene, the polypropylene being able to present a mixture of a homopolymer and a copolymer.